Synthetic resins



Patented Oct. 27, 1936 UNITED STATES PATENT OFFICE SYNTHETIC RESINS Henry S. Rothrock, Wilmington, Del., assignor to E. I. du Pont de Nemours & Company, Wilmington, Del., a corporation of Delaware No Drawing. Application April 3, 1935,

Serial No. 14,530

14 Claims. (Cl. 260-2) This invention relates to resinous materials n01 will require one mol of a dihalide. Variaand more particularly to new and improved polytions from chemically equivalent quantities. are other resins obtained by reacting certain dinot precluded, however, but the greater the vahydric phenols and organic polyhalides. riation, that is, excess of one or the other of 5 In the application of J. A. Arvin, Serial Numthe reactants, the less desirable will be the resin, 5 ber 651,634, filed January 13, 1933, there is disand if too highly unbalanced ratios are reached closed the'preparation of a new class of resins a high molecular weight polymer can no longer described as ether resins. These resins are obbe obtained. tained by reacting polyhydric phenols, or certain In the preferred embodiment of my invention 16 of their salts, with organic polyhalides whose the polynuclear dihydric phenol is mixed with halogen atoms are attached to aliphatic carbon an aqueous solution of the theoretical quantity, atoms. 01' a slight excess, of alkali and heated at a rela- In my investigations on resins of this charactively high temperature, above 70 C. and prefter I have discovered that if organic polyhalides erably above 100 C., but below the decomposiof the mentioned type are reacted with polytion temperature of the ingredients, with an 15 nuclear dihydric phenols of the kind described equivalent amount of the dihalide. The appabelow resins are obtained which have markedly ratus preferably consists of a vessel fitted with higher softening temperatures than those pr'ea thermometer, a reflux condenser, and a stirrer viously prepared. This improvement in resins designed to sweep the sides and bottom of the ofthe present type very considerably enhance vessel. Heating is continued until the desired their utility in the arts. state of condensation is obtained or until as This invention has as an object the prepara much of the phenol and dihalide are reacted as tion of new and useful resins. A further obpossible The phenol is taken to be largely Te; ject is the preparation of new resins of the kind acted when the alkalinity of the mixture rementioned above which are characterized by mains'sub tant a y Constant; Where the 25 higher softening temperatures than possessed by retieal amount o a ali was originally used, the ether resins heretofore prepared. Other obth fi a product is a y t a In vi w jects will appear hereinafter. of the fact that side reactions will occur, this The above objects are accomplished by method of following the progress of the resinifiso densing aliphatic polyhalides of the kind de-. cation is y appr x at T a t a scribed in the above identified application with also be fellOWed by distilling a few drops f t a polynuclear dihydric phenol containing an alreaction mixture and eXaminihg the Co d di kyl substituted cyclohexane ring, the phenolic tillate. If the distillate is cloudy some of the hydroxyls in said henol'bein atta h d t difhalide is uncombined and refluxing is continued.

ferent carbocyclic nuclei. A phenol of this kind When the ate is clear, the water can be 35 may berepresented by the general formula; distilled off without loss of halide; this will then permit the use of higher temperatures in the later stages of the reaction with a resultant R C decrease in time of preparation. Further heat-' 40 ing after the distillate becomes clear is gener- 40 U ally necessary, inasmuch as this clear point only shows that essentially all of the halide has com- 1253 1 112 R 15 an alkyl Substltuted cyclohexane binedby elimination of at least one of its halo- 1 gen atoms, but not necessarily all of them. The

The pelyhahdes referred to above Wlth Winch final reaction product is generally very viscous, 45 the Speelfied Phenols are reacted are orgamc and is opaque due to occluded salt. When the compounds containing at least two halogen atoms reaction mixture has reached the desired attached to different carbon atoms which are gree of condensation, r when alkahnity in tu joined to Other atoms by ingle bond proaches constancy, it is taken up while in the only. reaction vessel with a small amount of an aro- 50 y new resins are preferably made by reaetmatic hydrocarbon solvent, e. g., toluene and ins i a y equivalent qua tit of t orpoured on to trays while still hot and most of genie polyhalide and th alkali r a in arth the toluene distilled ofi. While still containing metal salt of the polynuclear dlhydric phenol. a small amount of toluene the product is trans- ,55 By this is meant that one mol of a dihydric pheferred, preferably in molten condition, to a The following examples are illustrative of resins of the kind disclosed and claimed herein:

Example I 4 Parts by weight (A) Sodium hydroxide (48.3% solution) 67.5 (B) Water 90.0

(C) 1,1-bis(4-hydroxyphenyl) 4 methylcyclohexane 112.8

(D) Bfi'dichlorodiethyl ether 57.3

Ingredients A, B and .C were placed in the order named in the reaction vessel and heated to refluxing with stirring. Ingredient D was then added slowly and refluxing continued for 16 hours, at the end of which time a few drops were distilled and found to be clear. Water was then distilled ofi, the temperature allowed to rise gradually to 235 C. where it was maintained for 4.5 hours with stirring. The resin was poured out of the reaction flask while hot, allowed to cool to room temperature, and dissolved in toluene. The solution was allowed to stand, the clear supernatant liquid decanted off, washed thoroughly with water, and then successively with dilute hydrochloric acid and water. The resin was recovered by evaporation of the toluene; and. dried by heating it in a vacuum oven for 24 hours at 110 C. A hard, somewhat friable resin softening at about 90 C., which showed no tendency to become either insoluble or infusible upon prolonged heating, was obcontinuously at 42-43 C. for 19 hours.

tained.

The 1,1-bis(4-hydroxyphenyl)-4-methylcyclohexane used in the above example was made as follows:

Twenty-eight (28) parts of 4-methylcyclohexplaced in a reaction vessel fitted with a, loop.

stirrer, thermometer, and condenser and stirred The paste-like semi-crystalline material was washed acid-free with water, and purified by repeated crystallizations from toluene. The product obtained melted at 178-179 C. and was identified as 1,1-bis(4-hydroxyphenyl)-4-methylcyclohexane.

Ingredient C of Example I may be replaced by a product obtained from phenol and commercial methylcyclohexanone, which contains the three isomers, and a resin of equally good charwith stirring to refluxing temperature.

acter obtained.

Example II Parts by weight (A) 1,1-bis(4-hydroxyphenyl) -3,5-dimethyl cyclohexane 71 (3) Sodium hydroxide (47.8% solution) 41 (C) Water 70 (D) p,;8-dichlorodiethyl ether 35 Ingredients A, B and C were placed in the order named-in the reaction vessel and heated Ingredient D'was then added slowly with stirring over temperature, dissolved in toluene, filtered, the

filtrate washed with water, and then successively with dilute hydrochloric acid and water. The resin was recovered by evaporation of the toluene, and dried by heating it in a vacuum oven for 18 hours at 120 C. The product ob"- tained was a hard, clear, pale yellow resin softening at about C.

amyl-cyclohexane 16 (B) Sodium hydroxide (47.65% solution)" 8 (C) Water 15 (D) fi, 3'-dichlorodiethyl ether 6.7

Ingredients A, B and C were placed in the order named in the reaction vessel and heated with stirring to refluxing temperature. Ingredient D was then added slowly and refluxing continued for 16 hours, at the end of which time a. test portion of distillate was clear. Water was then distilled off, the temperature allowed to rise gradually to 235 C. where it was maintained for 2.5 hours with stirring. The resin was allowed to cool to room temperature, dissolved in toluene, the solution filtered, washed with water, and then successively with dilute hydrochloric acid and water. The resin was recovered by evaporation of the toluene, and dried overnight in a steam oven at about C. The

product obtained was a light-colored resin softening at about 110 C.

The phenol used in Example II was prepared in accordance with application Serial Number 5,301, filed February 6, 1935, by reacting at slightly elevated temperatures (30-60 C.) phenol and 3,5-dimethylcyclohexanone in the presence of hydrogen chloride. The phenol used in Example III was similarly prepared by reacting phenol with 4-tertiary-amyl-cyclohexanone as disclosed and claimed in application Serial Number 5,299, filed February 6, 1935.

The phenols mentioned in the examples may be replaced by other phenols corresponding to the definition previously given, as for instance the various new phenols disclosed in the applications mentioned above. Examples of these phenols include such compounds as 1,1-bis(4- hydroxy-2-methylphenyl) -3,5 dimethylcyclohexane, 1,1-bis(4-hydroxyphenyl) -3,5-dibutylcyclohexane, 1,1 bis(4-hydroxyphenyl)-3-methyl-4- ethylcyclohexane, 1,l-bis(4-hydroxyphenyl)- 4 tertiary-butylcyclohexane, and 1,1-bis(4-hydroxyphenyl) -4-tertiary-heptylcyclohexane.

In place of the {3, B-dichlorodiethyl ether of the examples, other aliphatic polyhalides containing at least two halogen atoms attached to difierent carbon atoms which are in turn joined or potassium hydroxide or by other alkali metal hydroxides. Alkaline earth metal hydroxides may also be used, but a lesser degree of success is obtained because of .the poor solubilites of the phenolic salts.

As previously explained under the general description of my process, it-is'advantageous to purify my new resins by adding thereto a small amount of toluene while the resin is still in the reaction vessel, then pour the mixture into a heated Werner-Pileiderer mixer, neutralize it with dilute hydrochloric acid, and finally wash the product with hot water until it is salt-free.

The resin may then be dried either in the Werner-Pfleiderer mixer or under a vacuum. This improved procedure for washing out salt from high softening polyether resins is described more specifically below.

To the unpurified molten resin of Example I is added -10% of toluene. The mixture is poured, while still hot, on to a tray and the major portion of the toluene removed by heating in a vacuum oven. The resin, while still in a molten condition and containing a small amount of toluene, is poured into a steamjacketed Werner-Pfleiderer mixer and washed with hot water to remove salt, then washed with dilute hydrochloric acid, and finally washed free of chlorides with hot water. The salt-free resin is then transferred to a tray and vacuum dried overnight at about 120-130 C.

While the method just described for obtaining the purified resins is particularly advantageous in connection with the high softening type of polyether resin described herein, it may also be advantageously used in the purification of low melting types of polyether resinsl The surprising feature of this method is that even though the solvent used to plasticize the resin is volatile it is retained so tenaciously that there is substantially no loss thereof throughout the washing procedure. In place of the toluene of the above example I may use other polyether resin solvents, e. g., benzene, xylene, etc.

The importance of the alkyl substituent on the cyclohexane nucleus of the phenol, as it affects the softening point of the polyether resins,

made therefrom. is shown by the fact that the phenol used in Example I, namely, 1,1-bis(4-hydroxyphenyl)-4-methylcyclohexane, of the formula nyD'cyclohexane, which contains a methyl group oneach-benzene ring.

It'will be observed also that the resin of Example III, made from a phenol having the methyl by the tertiary alkyl group 11921 02155, has a softening point of 110 C. as compared to 80 C. for the resin made from the similar phenol having the cyclohexane group unsubstituted. This is very unexpected since the normal influence of increased aliphaticity is a lowering of the softening point.

The polyether resins of this invention are superior to similar resins known heretofore in having a higher softening temperature. This improved softening point is obtained without sacrifice in the excellent properties inherent to resins of this class such as good film-forming qualities, chemical inertness, good durability on outdoor exposure, toughness, and solubility in aromatic hydrocarbons. In view of their higher softening temperature, the field of utility of these resins is markedly greater than that of resins from phenols such as bis(4-hydroxyphenyl)dimethylmethane. These higher softening temperatures make it possible to .utilize the, new resins in applications for which former types of polyether resins were largely unsuited, e. g., all uses in which the resin must withstand moderate heat'without deformation. Among these are unsupported films (substitutes for thin transparent sheets of regenerated cellulose); fibers; linings for containers which are to be sterilized; glass substitutes for special uses such as automobile Windshields, nursing bottles, household dishes, molded electrical appliances, linings for battery jars, liners for chemical equipment, etc.; dentures; adhesives where the laminated objects are subjected to substantial temperatures such as washable double-textured fabric materials; certain types of molded articles such as pipe-stems, kitchen furniture, etc. In addition to these special uses, my new resins are also suited admirably for most of the uses disclosed in application Serial Number 651,634.

As many apparently widely different embodiments of this invention may be made without departing from the spirit and scope thereof, it is to be understood that I do not limit myself to the specific embodiments thereof except as defined in the appended claims.

I claim:

1. A polyether resin comprising the reaction product of ingredients comprising essentially a polyhydric phenol containing an alkyl substi tuted cyclohexane ring, the phenolic hydroxyls in said polyhydric phenol being attached to different carbocyclic nuclei, with an organic polyhalide whose halogen atoms are attached to different carbon atoms which are in turn joined to other atoms by single bonds only.

2. A polyether resin comprising the reaction product of an organic polyhalide whose halogen atoms are attached to different carbon atoms which are in turn joined to other atoms by single bonds only with an alkali metal salt of a phenol of the formula in which R is an alkyl substituted cyclohexane residue.

3. A polyether resin comprising the reaction product of an alkali metal salt of 1,1-bis(4-hy- I polyhalide whose halogen atoms are attached to difierent carbon atoms which are in turn joined to other atoms by single bonds only.

4. A polyether resin comprising the reaction product of an alkali metal salt of 1,1-bis(4-hydroxyphenyl)-3,5-dimethylcyclohexane and an organic polyhalide whose halogen atoms are attached to different carbon atoms which are in turn joined to other atoms by single bonds only.

5. A polyether resin comprising the reaction product of an alkali metal salt of 1,1-bis(4-hydroxyphenyl) -4-tertiary-amyl cyclohexane and an organic polyhalide whose halogen atoms are attached to difierent carbon atoms which are in turn joined to other atoms by single bonds only.

6. A process for making polyether resins which comprises reacting in polymerizing proportions ingredients comprising essentially a polyhydric phenol containing an alkyl substituted cycloh'exane ring, the phenolic hydroxyls in said polyhydric phenol being attached to different carbocyclic nuclei, with an organic polyhalide whose halogen atoms are attached to different carbon atoms which 'are in turn joined to other atoms by single bonds only.

'7. A process for making polyether. resins which comprises reacting in polymerizing proportions an organic polyhalide whose halogen atoms are attached to difierent carbon atoms which are in turn joined to other atoms by single bonds only with an alkali metal salt of a. phenol of the formula atoms by single bonds only.

droxyphenyl) methylcyclohexane and an organic V 9. A process for making resins which comprises reacting in polymerizing proportions the sodium salt of 1,l-bis(4-hydroxyphenyl)methylcyclohexane and p,fl'-dichlorodiethyl ether.

10. A process for making polyether resins which comprises reacting in polymerizing proportions an alkali metal salt of l,1-bis(4-hydroxyphenyl)- 3,5-dimethylcyclohexane and an organic polyhalide whose halogen atoms are attached to different atoms which are in turn joined to other atoms by single bonds only.

11. A process for making resins which comprises reacting in polymerizing proportions the sodium salt of 1,1-bis(4-hydroxyphenyl)-3,5-dimethylcyclohexane and ;3,fi'-dichlorodiethyl ether.

12. A process for making polyether resins which comprises reacting in polymerizing proportions an alkali metal salt of 1,1-bis(4-hydroxyphenyl) 4-tertiary-amyl-cyclohexane and an organic polyhalide whose halogen atoms are attached to different atoms whichare in turn joined to other atoms by single bonds only.

13. A process for making resins which comprises reacting in polymerizing proportions the sodium salt of 1,1-bis(4-hydroxyphenyl)-4-tertiary-amyl-cyclohexane and ,8,,8'-dichlorodiethyl ether.

14. A process for making polyether resins which comprises reacting in polymerizing proportions an organic polyhalide whose halogen atoms are attached to different carbon atoms which are in turn joined to other atoms by single bonds only with an alkali metal salt 'of a phenol of the formula HENRY S. RO'I'HROCK. 

